Abstract: A hood assembly for a vehicle includes an inner hood, an outer hood, and a deployable device. The outer hood is fixed relative to the inner hood and defines a gap between the inner hood and the outer hood. The deployable device is disposed in the gap. The deployable device defines an inflation chamber and is formed of thermoplastic elastomer. Upon detection of impact between the vehicle and a pedestrian, the deployable device is deployed to separate the outer hood and the inner hood. As such, during impact of the pedestrian with the outer hood, the outer hood may deform and/or the outer hood may space the pedestrian from relatively hard components under the hood assembly.

Abstract: A hood assembly for a vehicle includes an inner hood, an outer hood, and a plurality of deployable devices. The outer hood is fixed relative to the inner hood. The plurality of deployable devices are spaced apart from each other between the inner hood and the outer hood. The deployable devices each define an inflation chamber and are formed of thermoplastic elastomer. Upon detection of impact between the vehicle and a pedestrian, the deployable devices are deployed to separate the outer hood and the inner hood. As such, during impact of the pedestrian with the outer hood, the outer hood may deform and/or the outer hood may space the pedestrian from relatively hard components under the hood assembly.

Abstract: An airbag for a vehicle includes a hub, a first segment, a second segment, and a third segment. The first segment extends radially from the hub in a first direction. The second segment extends radially from the hub in a second direction different from the first direction. The third segment extends radially from the hub in a third direction different from the first direction and the second direction. When inflated in response to a sensed impact of the vehicle, the first segment, the second segment, and the third segment may extend from the hub between occupants of the vehicle to separate the occupants during the impact of the vehicle.

Abstract: A seat belt buckle assembly includes a buckle housing; a plate extending from the buckle housing and defining a slot; and a bracket including a rivet engaged in the slot. The plate and rivet are configured such that, in response to an impact force that exceeds a threshold acting to pull the buckle housing away from the bracket, the slot plastically deforms, permitting the buckle housing and plate to translate relative to the bracket.

Abstract: A seat belt assembly for a vehicle includes a pretensioner, and a cable connected to the pretensioner. The seat belt assembly includes a torsion bar having a plurality of teeth. The cable has slots interlocking with the teeth. During a sensed impact of the vehicle, the pretensioner is activated to retract the cable to pretension the seat belt assembly relative to an occupant of the vehicle. The interlocking of the slots with the teeth exerts torsional forces on the torsion bar, which yields to reduce forces on a chest of the occupant.

Abstract: An airbag for a vehicle includes a hub, a first segment, a second segment, and a third segment. The first segment extends radially from the hub in a first direction. The second segment extends radially from the hub in a second direction different from the first direction. The third segment extends radially from the hub in a third direction different from the first direction and the second direction. When inflated in response to a sensed impact of the vehicle, the first segment, the second segment, and the third segment may extend from the hub between occupants of the vehicle to separate the occupants during the impact of the vehicle.

Abstract: A hinge for a hood of a vehicle includes a first bracket, a member coupled to and rotatable relative to the first bracket, and a second bracket coupled to and rotatable relative to the member. An actuator includes a base connected to the first bracket and a rod moveable relative to the base. The rod moves from a retracted position to an extended position in contact with the second bracket.

Abstract: A vehicle includes a floor, a rear seat, and a front seat rotatable relative to the rear seat from a first position facing the rear seat to a second position facing away from the rear seat. An inflatable cushion is supported by the floor and is disposed between the front seat and the rear seat. A pressure control device is in communication with the inflatable cushion. The inflatable cushion may be used by an occupant of the vehicle as a footrest and/or a bed.

Abstract: A vehicle body includes a roof panel and a first bodyside panel. The roof panel includes first and second side regions. The first bodyside panel includes top and bottom regions. The roof panel and first bodyside panel define a continuous exterior surface region. The continuous exterior surface region extends from the first side region of the roof panel to the bottom region of the first bodyside panel through the second side region of the roof panel and top region of the first bodyside panel.

Abstract: An armrest is provided for a seat. That armrest includes a body and a deployable cup holder carried on the body. The deployable cup holder includes a translating base and an erectable well wall carried on the translating base. A seat assembly including an armrest is also disclosed.

Abstract: An airbag system includes an airbag. The airbag includes a face portion configured such that when the airbag is inflated; the face portion forms a corrugated section. The corrugated section has a plurality of corrugations. The plurality of corrugations is configured to impede movement of an occupant's head from a center of the airbag toward a side of the airbag during impact. The plurality of corrugations is formed using a plurality of tethers attached to the face portion.

Abstract: One-piece, integrated vehicle fascia and energy absorbers and methods of forming the same are disclosed. The one-piece vehicle fascia may include a fascia body and an energy absorber integrally formed with the fascia body. The energy absorber may include an open lattice portion including at least one lattice wall extending rearward from a front portion of the fascia body and adjoining at least two open cells. The lattice wall thickness may be smaller at a front portion of the energy absorber than at a rear portion. The open lattice portion may be formed as a honeycomb structure. The one-piece, integrated vehicle fascia and energy absorber may be formed by an additive manufacturing process (e.g., 3D printing). The process may include building the one-piece vehicle fascia in a plurality of successive layers each having a uniform thickness.

Abstract: A gap blocker assembly includes a support structure and a gap blocker panel operably coupled to the support structure. The gap blocker panel is movable to a substantially horizontal position to block a gap between a center console assembly and a seat.

Abstract: A beam module for a vehicle seat is mounted at a front of a seat, on top of a seat pan and underneath a seat cushion. The module includes a molded plastic beam. The module has a first shape substantially flush with the seat pan and a second shape projecting above the seat pan. The molded plastic beam has a mounting flange with a forward portion and a second portion. The molded plastic beam is inflatable. When inflated, the molded plastic beam assumes its second shape with the seat cushion being correspondingly displaced and deformed to raise the seat cushion when a frontal impact is detected.

Abstract: An active knee bolster for disposition in a motor vehicle dashboard includes a main bladder and a side bladder. The main bladder is formed of molded plastic and has an aperture therein at a first end. The main bladder also has a substantially flat undeployed shape and a deployed shape extending away from the dashboard. The side bladder is formed of molded plastic and has an open side. The open side is disposed over the aperture in the main bolster front panel and is sealingly connected to the main bladder. The side bladder has a substantially flat undeployed shape substantially flush with the undeployed shape of the main bolster. The side bladder has a deployed shape extending away from the main bladder.

Abstract: A bumper assembly includes a bumper beam, an actuator, and a lower stiffener. The actuator includes a base mounted to the bumper beam, and a rod moveably engaged with the base along a vertical axis. The lower stiffener is fixed to the rod. Depending on pre-determined vehicle speeds, the lower stiffener moves from a deployed position to a retracted position based on pedestrian leg impact considerations and to reduce the likelihood of lower stiffener damage.

Abstract: An aluminum alloy vehicle structural component defining an out-of-plane aperture with its main portion. A recessed portion is inset from the main portion having a bed sub-portion out-of-plane with the main portion that defines the aperture. The recessed portion also provides a strain hardened sub-portion, or stiffened ring of material, around the aperture. When the main portion is subjected to in-plane tension due to bending, the strain primarily concentrates along the strain hardened sub-portion (the stiffened ring) and by-passes the aperture. As a result the perimeter of the aperture undergoes less straining than if the aperture was in-plane with the main portion. The out-of-plane aperture, the bed sub-portion surrounding the aperture, and the strain hardened sub-portion surrounding the bed sub-portion may improve the overall structural robustness of the aluminum alloy structural component when subjected to in-plane tension.

Abstract: A method of controlling a sunroof of a parked vehicle is provided. The method includes the steps of: monitoring a state of an engine; monitoring a state of the sunroof; monitoring a state of at least one accessory; initiating a timer when the state of the engine changes to an off state, the state of the sunroof is an open state, and the state of the at least one accessory is an off state; and closing the sunroof a period of time after initiation of the timer. The method may further include sensing for precipitation throughout the period of time, and closing the sunroof upon sensing precipitation regardless of whether the period of time has elapsed. The method may further include sensing for an occupant within the vehicle when the period of time has elapsed or when precipitation is sensed, and foregoing the step of closing the sunroof if an occupant is sensed.

Abstract: A crush-can is provided. That crush-can includes a first wall, a second wall within the first wall and a corrugated core between the first wall and the second wall. A method for producing the crush-can via 3D printing is also disclosed.

Abstract: Systems for providing for an external vehicle airbag to mitigate the negative effects of vehicle rollover are described. In an exemplary implementation, one or more airbags are disposed inside the roof rails attached to a vehicle roof. In the event of a vehicle rollover, the airbags will deploy and extend downward along the sides of the vehicle. The airbags may be held in desirable deployed position by one or more elastic tethers.